DC ARC welding aluminum

[chuck hahn]

Tried the alloy rods and MAPP gas on a case. Was useless as the cases are so thick and big they suck the local heat away and I never achieved the melting point for the rods to stick. Something small like a points cover may be a different story though.

[Lorenzo]

It's not the easiest thing to do;

You have to bring the part to almost melting point temp. without exposing the rod, which has to melt with the heat given by the part, not the torch, least it will oxidize itself, oxide (Alumina) which is going to melt at 2000ì°C/3632°F against 660°C
/1220°F of alu.

Did you use any flux?

[tatu]

MAPP gas?
Also propane will work, if you are to braze solder.
For that I would recommend to flux the part/s
Sorry, no help for the OP and is question (although I deem it not worth the hassle, even if it were free).

No MAPP gas is little more than a blow lamp and hopeless for any kind of welding/brazing. I just checked and Propolene is the substitute for Acetylene used. I use these people: http://www.gas-uk.co.uk/ Check their rent free cylinders I got the 20 litre size still on the first fill and there is still plenty in them and I must have got them 2 years ago

[hampshirehog]

I was shown this link by a friend that bought some of this stuff, he hasn't used it yet but we're all keen to see the results.

https://www.youtube.com/watch?v=aiThO-UQIWE

That's good stuff. The guy in the video repaired a carb float pin for us at Netley a few years ago (mate bought a beat up old carb body at the show and deliberately snapped the pin to see if it would work). I've got a metre of the stuff in the garage and although I've had a play with it I haven't had a use for it in earnest yet - I'm keen to see how it works in a bolt hole to repair a knackered thread.

[rustybronco]

Chuck, there was a guy I used to work with who was good at stick welding aluminum. I had a cracked case cover on my old 500 Kaw that he welded for me. He went out back, flipped the welder on DC+ and laid a bead like no other. I've TIG'd it back in high school. Welded it with oxy-acetelene in the distant past using a carburizing flame, but I have yet to try my hand at SMAW welding it. Someday...

[chuck hahn]

Yes Dale. I need to repair a broke engine mount on the Nighthawk project. Soon as thats done i can proeceed with setting the engine in the frame and getting the drives haft and swing arm installed.

I dont have a TIG and dont have the funds to just go buy one....so its look at alternatives to actually taking it to a shop and paying who knows what. I basically need 2 welds a bout 1 inch long and its done. I have ground ditches in the case and the replacement bracketry. The base metal is pretty thick there as the area is at the right rear corner of the case where its good and thick.

Was gonna do a little run and stop to let it cool. Do some more and let that cool. Do this till I have both sides welded decently and go from there is the basic plan of attack.

[rustybronco]

I'm going to guess those two little welds will cost you about $50.

[Nessism]

I'm going to guess those two little welds will cost you about $50.

From an experienced welder that knows what they are doing. Pay the man.

[chuck hahn]

gonna eventually get the rods and take some old scrap cover and play a while before tackling the mount. It will all be ok..I aint skeart!!!